Process Engineering HAZOP Procedure: Petroleum Development Oman L.L.C
Process Engineering HAZOP Procedure: Petroleum Development Oman L.L.C
Process Engineering HAZOP Procedure: Petroleum Development Oman L.L.C
Process Engineering
HAZOP Procedure
User Note:
The requirements of this document are mandatory. Non-compliance shall only be authorised by
the Document Owner or his Delegate through STEP-OUT approval.
A controlled copy of the current version of this document is on PDO's EDMS. Before making
reference to this document, it is the user's responsibility to ensure that any hard copy, or
electronic copy, is current. For assistance, contact the Document Custodian or the Document
Controller.
Users are encouraged to participate in the ongoing improvement of this document by providing
constructive FEDback.
i Revision History
The following is a brief summary of the 4 most recent revisions to this document. Details of all
revisions prior to these are held on file by the issuing department.
TABLE OF CONTENTS
i Revision History...................................................................................................................... 3
ii Related Business Processes .................................................................................................. 3
iii Related Corporate Management Frame Work (CMF) Documents ........................................ 3
1 Introduction ............................................................................................................................. 5
1.1 Abbreviations .................................................................................................................... 5
1.2 Background ...................................................................................................................... 5
1.3 Purpose ............................................................................................................................ 5
1.4 Scope................................................................................................................................ 6
1.5 Objective ........................................................................................................................... 6
1.6 Fundamentals of this Procedure....................................................................................... 6
1.7 Distribution/Target Audience ............................................................................................ 6
1.8 Review and Improvement ................................................................................................. 6
1.9 Deviations from this Procedure ........................................................................................ 6
2 Roles and Responsibilities ..................................................................................................... 7
2.1 PDO Process Engineering Discipline ............................................................................... 7
2.2 PDO Project Engineer ...................................................................................................... 7
2.3 Contractor Project Engineer ............................................................................................. 8
2.4 HAZOP Leader ................................................................................................................. 8
2.5 General ............................................................................................................................. 9
2.6 Drawings and Templates ................................................................................................ 10
2.7 Design Review and Main HAZOP................................................................................... 12
Appendix 1 HAZOP Worksheet .................................................................................................. 13
Appendix 2 HAZOP Action Response Form ............................................................................... 15
Appendix 3 HAZOP Team Member FEDback Form .................................................................. 16
Appendix 4 HAZOP Introduction Presentation ........................................................................... 17
1 Introduction
1.1 Abbreviations
BFD Basis For Design
C&A Control and Automation
CFDH Corporate Function Discipline Head
EP Exploration & Production
ERD Engineering Reference Document
FED Front End Design (“Define” phase)
F&G Fire and Gas
HAZOP Hazard and Operability (Study)
HFP Hazard and Operability Studies Focal Point
HL Hazard and Operability Study Leader(s)
OPMG Opportunity and Project Management Guide
PE Project Engineer(s)
PEFS Process Engineering Flow Scheme (Shell terminology, same as P&ID)
PFS Process Flow Scheme
PSFS Process Safeguarding Flow Scheme
PR PDO Procedure
TA Technical Authority
UEF Process Engineering Discipline functional indicator in PDO, as of 2006
1.2 Background
Safety is a primary focus for all plant design and operation.
Hazard and Operability Studies (HAZOPs) are a key component in ensuring safety. Hence
satisfactory HAZOP execution and follow-up are critical to business performance.
This procedure is one part of a continued effort to improve the execution of HAZOPs in PDO.
1.3 Purpose
This document serves the following purposes:
1. It gives roles and responsibilities documenting how the Shell HSE Manual EP95-0313
HAZOP is implemented in PDO.
2. It gives clarifications, additions and amendments to EP95-0313, based on best industry
practice, local contracting arrangements, past history and past experience.
3. Templates are given for relevant PDO documents, for consistency.
It is not the intention to duplicate the contents of EP95-0313. It is assumed that the reader of this
procedure already knows EP95-0313.
1.4 Scope
This procedure covers the full lifecycle of any HAZOP study, from preparation to closeout. Its
use is mandatory for all persons involved in HAZOP studies and by all projects. Terminology is
as follows:
• Shall indicates mandatory requirement
• Should indicates preference
1.5 Objective
The objective of this document is to achieve more effective project planning and shorter project
execution and delivery. It gives a clear procedure on how PDO does HAZOPs, thus preventing
misunderstandings among the involved parties.
This objective will be achieved by the process discipline taking closer ownership of the entire
HAZOP process and quality.
2.5 General
• The responsibility of the HL is to carry out an objective HAZOP study, regardless of project
pressures. Therefore the HL shall be independent from the design team and shall not accept
an assignment where there is an actual or implied conflict of interest etc. (see Section 2.1
and 2.2). Hence when the project involves a design contractor, the HL should be selected
from outside the contractor’s team, wherever this is possible.
• The maximum number of members present in a HAZOP study at any one time shall be 12,
except for the introduction on the first day. If more than 12 persons are required, the non-
core members should be called in as and when required. If more than 12 persons are still in
the room after the introduction the HL shall decide who is not required and shall not start
until the number is 12 or less.
In special cases, if >12 persons absolutely cannot be avoided, such as for complex projects
with multiple contractors, an approved variance to this procedure will be required prior to
starting the HAZOP, see Section 1.9.
• HAZOP duration shall be estimated using L=1.5 for inexperienced leaders, from EP95-0313,
Table 3.3.
• The Process Engineering Discipline will approve HL by 2 pathways:
o PDO-approved HAZOP course + training in this procedure + completion of at least
one satisfactory HAZOP which will be monitored by an already-approved HL
assigned as mentor.
o Personal interview with Process CFDH demonstrating ability, knowledge of EP95-
0313 and of this procedure.
• Team members should normally not be duplicated between PDO and Contractor, for
disciplines other than Process Engineering and C&A Engineering.
• The HAZOP Secretary shall meet the following minimum standards:
o Attendance at 3 previous HAZOPs as team member
o Adequate ability to understand and type in English
o Working in oil & gas industry for a minimum of 2 years in a technical role
The HAZOP Secretary should be capable of filling in the HAZOP worksheet without needing
to be dictated to by the Leader or others, as this greatly reduces the quality of the study by
diverting attention. To do so, he must understand the discussion, hence the minimum
standards above. If the HAZOP Secretary is shown to be inadequate to the task, the HL
shall give his duties to another HAZOP team member and excuse him from the study.
• The HAZOP shall not start, or continue, without these following persons (as well as the
Leader and the Secretary) being present in the room, all of whom must be thoroughly
familiar with the project and not last-minute substitutes:
o PDO Process Engineer
o Contractor Process Engineer
o C&A Engineer (PDO or Contractor)
o Operators Representative
This is a minimum benchmark, normally more people will be required.
• A HAZOP introduction shall be provided at the start of any HAZOP study (typically lasting
approx 2 hours for a 5 day HAZOP), unless all the HAZOP team members have been to the
Design Review and this design review covered all the bullet points listed below. In the
HAZOP introduction, presentations shall be given by the following persons
o HAZOP Leader:
Before other disciplines: welcome, introduction to HAZOP, identify persons
new to PDO HAZOP, check all are available for duration.
After other disciplines: explain guidewords, briefly describe all nodes and
agree them with HAZOP team, refer to (Appendix-4) for an Introduction
Presentation.
o Process Engineer: describe scope of study, overall process flow, mass balance,
pressures, temperatures and other major safety risks (e.g. H2S, steam); point out
locations of main design condition and materials spec changes.
o Project Engineer: explain project objectives, purpose of HAZOP within project,
outline previous reviews (e.g. Design Review and Coarse HAZOP) and highlight
still-open actions, commercial, technical, schedule constraints and issues, plot plan
layout.
o C&A Engineer: describe overall process control, discuss different control modes if
applicable, process and emergency shutdown causes and effects, F&G system.
o Operators Representative: give past experience with similar plant, manning, what is
expected operators involvement in plant operation, started-up and shutdown, also
list any concerns about the design.
• An introduction shall be provided for each node, at the start of the review of that node. This
normally takes the format of the HL or the Process Engineer going through the node’s
features, including a review of the HAZOP worksheet header (Appendix 1).
• As per EP95-0313, Section 2.12.2 “representation from eventual operators of the plant is
essential” at a HAZOP. It should be clear that eventual operators of the plant are not the
support engineers based in the Muscat office, but rather field-based personnel, or
alternatively ex-field based personnel familiar with that location and practices.
• When a HAZOP is not required: refer to Figure 3.2 of EP95-0313.
• The HAZOP venue is important and shall be selected according to these criteria:
o Size - the room shall be of size appropriate to the number of attendees. Rooms that
are too large are inappropriate: it is difficult to see even the A0-size drawings stuck
on walls, difficult to hear people (also due to noisy air conditioning), team does not
interact efficiently and side-discussions proliferate.
o Wall space: there shall be sufficient blank walls for attaching the A0 drawings. Many
rooms, particularly in hotels, are unsuitable due to drapes, pillars and other
adornments.
o Seating: this should be so that all HAZOP members can see each other.
o Either a whiteboard (not used for projecting) or a paper flip chart should be available
to assist in discussions.
o The only changes allowed to the worksheets after finishing the HAZOP study and
with the Leader not present shall be cosmetic, i.e. restricted to formatting, drafting,
spelling etc. No changes shall be made that could change the meaning of the
content.
o HAZOP worksheets do not get signed.
o “Priority” as on the worksheet shall be for both schedule priority and risk priority, see
EP95-0313, Section 4.1.1. The more severe criterion applies.
• HAZOP drawings shall have the following features:
o The HL shall use an A1 or A0 set of PEFS attached to walls of the meeting room to
mark up nodes, lead discussion, and to mark up all the changes to PEFS resulting
from HAZOP actions up to present time. All the drawings should be displayed, if
possible in a sequence from left to right. This set gets discarded after the end of
HAZOP, after checking that all information is transferred to the A3s.
o The Master Set of HAZOP PEFS shall be of A3 size. Any change agreed to at the
HAZOP which affects the PEFS shall be marked up on the Master Set. This can be
done at the end of each day or at the end of the study, or afterwards by transferring
markups from the A0 drawings. It does not matter, as the Master Set is not used
during the HAZOP.
The Master Set is not the definitive record of the HAZOP – worksheets are the
definitive record. The purpose of the Master Set is to allow for a quick and
convenient overview of the impact of the HAZOP study on the project, without
having to read the worksheets. It shall be stamped and signed off by HL as the
HAZOP study Master Set of PEFS. It shall be attached to the HAZOP Report.
• HAZOP Report preparation shall have the following features:
o Structure and contents exactly as per Section 4.3 of EP95-0313.
o Routing:
1. Contractor PE or delegate shall prepare a draft HAZOP Report within 1 week of
the study. Contractor PE shall check it and sends it to both HL and PDO PE for
comment.
2. HL and PDO PE shall comment on the draft (no need to approve the draft). The
HL and PDO PE shall be given 1 week for comments, if no comments are
received in this time then the contractor shall assume that there are no
comments and proceed.
3. Contractor PE shall prepare the final HAZOP Report, sign it and send it to HL.
4. HL approves the HAZOP Report (or go back to 3) and sends it to PDO PE. This
shall be done within 3 weeks of completion of the HAZOP.
5. PDO PE signs it to indicate acceptance (or go back to 4).
• HAZOP Action Response Forms shall have the following features (Appendix 2):
o One action per form.
o After implementing the close out action, the Discipline Engineer signs the Action
Response Form. Any evidence of action being closed out (such as marked up
PEFS, cover of relevant calculation, or page from updated operating philosophy)
shall be attached.
o Signature by the Contractor Discipline Engineer and Contractor PE is required for all
closed Contractor Action Response Forms.
o Signature by PDO Process Engineer (with TA-2) and PDO PE is required for all
closed Action Response Forms.
o Only the PDO HAZOP worksheet template shall be used (Appendix 2). The sheet
has a header identical to the HAZOP Worksheet, as simplified cutting/pasting will
minimize content errors.
• HAZOP Action Close Out Status Report:
o This shall be a simple list of all HAZOP actions, by number, indicating their status as
Closed or Not Closed.
o The purpose of this list is to give an overview of the close out status at the end of
FED.
By Priority No.
who? 1,2,3 seq.
Operability Operator access
Maintenance access
Relief & blowdown
Emergency shutdown
Process shutdown
Draining
Venting
Isolation
Purging
Commissioning
Start-up
Materials of construc.
Sample points
Instruments
Degree of automation
Normal operation or
maintenance
Failed operation or
maintenance
Different operating
modes
Other
PROJECT:____________________________________________________________________________________
HAZOP Date:__________________________________________________________________________________
Very
Good Average Bad Very Bad
Good
What was the maximum number of persons in the room at any one time (other than for
……………persons
Introduction)?
Comments:
If you ticked Bad or Very Bad boxes, please provide more information so we can follow this up.
Thank you